Elastic composite formed from multiple laminate structures

ABSTRACT

An elastic composite formed from a laminate that contains an elastic film and a lightweight nonwoven facing having a low strength in the cross-machine direction (“CD”) is provided. Due to the low strength of the facing, it is desirable that the elastic film have a sufficient thickness and weight to enhance the strength of the resulting composite. Unfortunately, the ability to join an elastic film to such a lightweight nonwoven facing becomes increasingly difficult as the thickness of the film increases. In this regard, the present inventors have discovered that a second laminate may be employed in the elastic composite that is formed from a thermoplastic film and nonwoven facing to impart increased strength to the composite. The film and facing of the second laminate may be formed from the same or different materials than the film and facing of the first laminate. Regardless, the laminates are positioned so that the elastic and thermoplastic films are in a face-to-face relationship. Through selective control over the polymer content and thickness, the present inventors have discovered that the elastic and thermoplastic films may be readily joined together under light pressure, even at ambient temperature conditions. This avoids the application of a substantial amount of heat used in conventional calender bonding processes, which can otherwise damage the film, and also minimize the need for costly adhesives.

BACKGROUND OF THE INVENTION

Elastic composites are commonly incorporated into products (e.g., diapers, training pants, garments, etc.) to improve their ability to better fit the contours of the body. For example, the elastic composite may be formed from an elastic film and a nonwoven facing. The nonwoven facing may be bonded to the elastic film through the application of heat and pressure (e.g., calender rolls) while the film is in a stretched condition so that the nonwoven facing can gather and form “pleats” between the locations where it is bonded to the film when it is retracted. The resulting elastic composite is stretchable to the extent that the pleats allow the elastic film to elongate. To reduce costs, it is desirable to form such composites with nonwoven facings having a low basis weight and strength. Unfortunately, however, facings that are low in strength are difficult to manufacture due to their lack of durability and integrity. For example, the heat and pressure applied by conventional calender rolls can significantly damage the integrity of the facing. Furthermore, higher basis weight facings are often required for durability due to the gathering of the material during lamination.

As such, a need currently exists for an elastic composite that is formed from a lightweight and low strength nonwoven facing, yet is also sufficiently durable for effective use in various applications.

SUMMARY OF THE INVENTION

In accordance with one embodiment of the present invention, an elastic composite is disclosed. The composite comprises a first laminate that contains a first nonwoven facing and an elastic film. The first nonwoven facing has a basis weight of about 45 grams per square meter or less and a peak load of about 350 grams-force per inch or less in the cross-machine direction. The composite further comprises a second laminate containing a second nonwoven facing and a thermoplastic film. The first laminate and second laminate are joined together so that the elastic film is bonded and positioned adjacent to the thermoplastic film.

In accordance with another embodiment of the present invention, a method of forming an elastic composite is disclosed. The method comprises extruding an elastomeric composition directly onto a surface of a first nonwoven facing to form an elastic film and allowing the film to bond to the facing to form a first laminate. The first nonwoven facing has a basis weight of about 45 grams per square meter or less and a peak load of about 350 grams-force per inch or less in the cross-machine direction. The first laminate is joined to a second laminate containing a second nonwoven facing and a thermoplastic film so that the elastic film is bonded and positioned adjacent to the thermoplastic film.

Other features and aspects of the present invention are described in more detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, which makes reference to the appended figures in which:

FIG. 1 schematically illustrates a method for forming a composite according to one embodiment of the present invention;

FIG. 2 is a cross-sectional illustration of one embodiment of the composite of the present invention;

FIG. 3 is a perspective view of a personal care product that may be formed in accordance with one embodiment of the present invention;

FIG. 4 is a perspective view of grooved rolls that may be used in one embodiment of the present invention; and

FIG. 5 is a cross-sectional view showing the engagement between two of the grooved rolls of FIG. 4.

Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention.

DETAILED DESCRIPTION OF REPRESENTATIVE EMBODIMENTS Definitions

As used herein the term “nonwoven web” generally refers to a web having a structure of individual fibers or threads which are interlaid, but not in an identifiable manner as in a knitted fabric. Examples of suitable nonwoven fabrics or webs include, but are not limited to, meltblown webs, spunbond webs, bonded carded webs, airlaid webs, coform webs, hydraulically entangled webs, and so forth.

As used herein, the term “meltblown” web or facing generally refers to a nonwoven web that is formed by a process in which a molten thermoplastic material is extruded through a plurality of fine, usually circular, die capillaries as molten fibers into converging high velocity gas (e.g., air) streams that attenuate the fibers of molten thermoplastic material to reduce their diameter, which may be to microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers. Such a process is disclosed, for example, in U.S. Pat. No. 3,849,241 to Butin, et al., which is incorporated herein in its entirety by reference thereto for all purposes.

As used herein, the term “spunbond” web or facing generally refers to a web containing small diameter substantially continuous fibers. The fibers are formed by extruding a molten thermoplastic material from a plurality of fine, usually circular, capillaries of a spinnerette with the diameter of the extruded fibers then being rapidly reduced as by, for example, eductive drawing and/or other well-known spunbonding mechanisms. The production of spunbond webs is described and illustrated, for example, in U.S. Pat. No. 4,340,563 to Appel, et al., U.S. Pat. No. 3,692,618 to Dorschner, et al., U.S. Pat. No. 3,802,817 to Matsuki, et al., U.S. Pat. No. 3,338,992 to Kinney, U.S. Pat. No. 3,341,394 to Kinney, U.S. Pat. No. 3,502,763 to Hartman, U.S. Pat. No. 3,502,538 to Levy, U.S. Pat. No. 3,542,615 to Dobo, et al., and U.S. Pat. No. 5,382,400 to Pike, et al., which are incorporated herein in their entirety by reference thereto for all purposes. Spunbond fibers are generally not tacky when they are deposited onto a collecting surface. Spunbond fibers often have a diameter of from about 10 to about 20 micrometers.

As used herein, the terms “machine direction” or “MD” generally refers to the direction in which a material is produced. The term “cross-machine direction” or “CD” refers to the direction perpendicular to the machine direction.

As used herein, the “hysteresis value” of a sample may be determined by first elongating the sample (“load up”) and then allowing the sample to retract (“load down”). The hysteresis value is the loss of energy during this cyclic loading.

DETAILED DESCRIPTION

Reference now will be made in detail to various embodiments of the invention, one or more examples of which are set forth below. Each example is provided by way of explanation, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations may be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment, may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention cover such modifications and variations.

Generally speaking, the present invention is directed to an elastic composite formed from a laminate that contains an elastic film and a lightweight nonwoven facing having a low strength in the cross-machine direction (“CD”). Due to the low strength of the facing, it is desirable that the elastic film have a sufficient thickness and weight to enhance the strength of the resulting composite. Unfortunately, the ability to join an elastic film to such a lightweight nonwoven facing becomes increasingly difficult as the thickness of the film increases. In this regard, the present inventors have discovered that a second laminate may be employed in the elastic composite that is formed from a thermoplastic film and nonwoven facing to impart increased strength to the composite. The film and facing of the second laminate may be formed from the same or different materials than the film and facing of the first laminate. Regardless, the laminates are positioned so that the elastic and thermoplastic films are in a face-to-face relationship. Through selective control over the polymer content and thickness, the present inventors have discovered that the elastic and thermoplastic films may be readily joined together under light pressure, even at ambient temperature conditions. This avoids the application of a substantial amount of heat used in conventional calender bonding processes, which can otherwise damage the film, and also minimize the need for costly adhesives.

In this regard, various embodiments of the present invention will now be described in more detail.

I. First Laminate

A. Nonwoven Facing

As stated above, the nonwoven facing of the first laminate is generally lightweight and has a low degree of strength in the cross-machine direction (“CD”), which increases the flexibility of the composite and also provides significant costs savings in its manufacture. More specifically, the basis weight may range from about 45 grams per square meter or less, in some embodiments from about 1 to about 30 grams per square meter, and in some embodiments, from about 2 to about 20 grams per square meter. Likewise, the nonwoven facing may have a peak load in the cross-machine direction of about 350 grams-force per inch (width) or less, in some embodiments about 300 grams-force per inch or less, in some embodiments from about 50 to about 300 grams-force per inch, in some embodiments from about 60 to about 250 grams-force per inch, and in some embodiments, from about 75 to about 200 grams-force per inch. If desired, the nonwoven facing may also have a low strength in the machine direction (“MD”), such as a peak load in the machine direction of about 3000 grams-force per inch (width) or less, in some embodiments about 2500 grams-force per inch or less, in some embodiments from about 50 to about 2000 grams-force per inch, and in some embodiments, from about 100 to about 1500 grams-force per inch.

The nonwoven facing may be formed from a variety of known processes, such as meltblowing, spunbonding, carding, wet laying, air laying, coform, etc. In one particular embodiment, for example, the nonwoven facing is a meltblown facing that contains “microfibers” in that they have an average size of about 15 micrometers or less, in some embodiments from about 0.01 to about 10 micrometers, and in some embodiments, from about 0.1 to about 5 micrometers.

Regardless of the manner in which it is formed, the nonwoven facing is typically formed from a polymer having a relatively high Vicat softening temperature (ASTM D-1525), such as from about 100° C. to about 300° C., in some embodiments from about 120° C. to about 250° C., and in some embodiments, from about 130° C. to about 200° C. Exemplary high-softening point polymers for use in forming nonwoven facings may include, for instance, polyolefins, e.g., polyethylene, polypropylene, polybutylene, etc.; polytetrafluoroethylene; polyesters, e.g., polyethylene terephthalate and so forth; polyvinyl acetate; polyvinyl chloride acetate; polyvinyl butyral; acrylic resins, e.g., polyacrylate, polymethylacrylate, polymethylmethacrylate, and so forth; polyamides, e.g., nylon; polyvinyl chloride; polyvinylidene chloride; polystyrene; polyvinyl alcohol; polyurethanes; polylactic acid; copolymers thereof; blends thereof; and so forth. It should be noted that the polymer(s) may also contain other additives, such as processing aids or treatment compositions to impart desired properties to the fibers, residual amounts of solvents, pigments or colorants, and so forth.

Monocomponent and/or multicomponent fibers may be used to form the nonwoven facing. Monocomponent fibers are generally formed from a polymer or blend of polymers extruded from a single extruder. Multicomponent fibers are generally formed from two or more polymers (e.g., bicomponent fibers) extruded from separate extruders. The polymers may be arranged in substantially constantly positioned distinct zones across the cross-section of the fibers. The components may be arranged in any desired configuration, such as sheath-core, side-by-side, pie, island-in-the-sea, three island, bull's eye, or various other arrangements known in the art. Various methods for forming multicomponent fibers are described in U.S. Pat. No. 4,789,592 to Taniguchi et al. and U.S. Pat. No. 5,336,552 to Strack et al., U.S. Pat. No. 5,108,820 to Kaneko, et al., U.S. Pat. No. 4,795,668 to Kruege, et al., U.S. Pat. No. 5,382,400 to Pike, et al., U.S. Pat. No. 5,336,552 to Strack, et al., and U.S. Pat. No. 6,200,669 to Marmon, et al., which are incorporated herein in their entirety by reference thereto for all purposes. Multicomponent fibers having various irregular shapes may also be formed, such as described in U.S. Pat. No. 5,277,976 to Hogle, et al., U.S. Pat. No. 5,162,074 to Hills, U.S. Pat. No. 5,466,410 to Hills, U.S. Pat. No. 5,069,970 to Largman, et al., and U.S. Pat. No. 5,057,368 to Largman, et al., which are incorporated herein in their entirety by reference thereto for all purposes.

The desired denier of the fibers used to form the nonwoven facing may vary depending on the desired application. Typically, the fibers are formed to have a denier per filament (i.e., the unit of linear density equal to the mass in grams per 9000 meters of fiber) of less than about 6, in some embodiments less than about 3, and in some embodiments, from about 0.5 to about 3.

Although not required, the nonwoven facing may be optionally bonded using any conventional technique, such as with an adhesive or autogenously (e.g., fusion and/or self-adhesion of the fibers without an applied external adhesive). Suitable autogenous bonding techniques may include ultrasonic bonding, thermal bonding, through-air bonding, calender bonding, and so forth. The temperature and pressure required may vary depending upon many factors including but not limited to, pattern bond area, polymer properties, fiber properties and nonwoven properties. For example, the facing may be passed through a nip formed between two rolls, both of which are typically not patterned i.e., smooth. In this manner, only a small amount of pressure is exerted on the materials to lightly bond them together. Without intending to be limited by theory, the present inventors believe that such lightly bonded materials can retain a higher degree of extensibility and thereby increase the elasticity and extensibility of the resulting composite. For example, the nip pressure may range from about 0.1 to about 20 pounds per linear inch, in some embodiments from about 1 to about 15 pounds per linear inch, and in some embodiments, from about 2 to about 10 pounds per linear inch. One or more of the rolls may likewise have a surface temperature of from about 15° C. to about 60° C., in some embodiments from about 20° C. to about 50° C., and in some embodiments, from about 25° C. to about 40° C.

The nonwoven facing may also be stretched in the machine and/or cross-machine directions prior to lamination to the film of the present invention. Suitable stretching techniques may include necking, tentering, groove roll stretching, etc. For example, the facing may be necked such as described in U.S. Pat. Nos. 5,336,545, 5,226,992, 4,981,747 and 4,965,122 to Morman, as well as U.S. Patent Application Publication No. 2004/0121687 to Morman, et al. Alternatively, the nonwoven facing may remain relatively inextensible in at least one direction prior to lamination to the film. In such embodiments, the nonwoven facing may be optionally stretched in one or more directions subsequent to lamination to the film. The facing may also be subjected to other known processing steps, such as aperturing, heat treatments, etc.

B. Elastic Film

The elastic film of the first laminate is formed from one or more elastomeric polymers that are melt-processable, i.e., thermoplastic. Any of a variety of thermoplastic elastomeric polymers may generally be employed in the present invention, such as elastomeric polyesters, elastomeric polyurethanes, elastomeric polyamides, elastomeric copolymers, elastomeric polyolefins, and so forth. In one embodiment, for instance, a substantially amorphous block copolymer may be employed that contains blocks of a monoalkenyl arene and a saturated conjugated diene. Such block copolymers are particularly useful in the present invention due to their high degree of elasticity and tackiness, which enhances the ability of the film to bond to the nonwoven facing.

The monoalkenyl arene block(s) may include styrene and its analogues and homologues, such as o-methyl styrene; p-methyl styrene; p-tert-butyl styrene; 1,3 dimethyl styrene p-methyl styrene; etc., as well as other monoalkenyl polycyclic aromatic compounds, such as vinyl naphthalene; vinyl anthrycene; and so forth. Preferred monoalkenyl arenes are styrene and p-methyl styrene. The conjugated diene block(s) may include homopolymers of conjugated diene monomers, copolymers of two or more conjugated dienes, and copolymers of one or more of the dienes with another monomer in which the blocks are predominantly conjugated diene units. Preferably, the conjugated dienes contain from 4 to 8 carbon atoms, such as 1,3 butadiene (butadiene); 2-methyl-1,3 butadiene; isoprene; 2,3 dimethyl-1,3 butadiene; 1,3 pentadiene (piperylene); 1,3 hexadiene; and so forth. The amount of monoalkenyl arene (e.g., polystyrene) blocks may vary, but typically constitute from about 8 wt. % to about 55 wt. %, in some embodiments from about 10 wt. % to about 35 wt. %, and in some embodiments, from about 25 wt. % to about 35 wt. % of the copolymer. Suitable block copolymers may contain monoalkenyl arene endblocks having a number average molecular weight from about 5,000 to about 35,000 and saturated conjugated diene midblocks having a number average molecular weight from about 20,000 to about 170,000. The total number average molecular weight of the block polymer may be from about 30,000 to about 250,000.

Particularly suitable thermoplastic elastomeric copolymers are available from Kraton Polymers LLC of Houston, Tex. under the trade name KRATON®. KRATON® polymers include styrene-diene block copolymers, such as styrene-butadiene, styrene-isoprene, styrene-butadiene-styrene, and styrene-isoprene-styrene. KRATON® polymers also include styrene-olefin block copolymers formed by selective hydrogenation of styrene-diene block copolymers. Examples of such styrene-olefin block copolymers include styrene-(ethylene-butylene), styrene-(ethylene-propylene), styrene-(ethylene-butylene)-styrene, styrene-(ethylene-propylene)-styrene, styrene-(ethylene-butylene)-styrene-(ethylene-butylene), styrene-(ethylene-propylene)-styrene-(ethylene-propylene), and styrene-ethylene-(ethylene-propylene)-styrene. These block copolymers may have a linear, radial or star-shaped molecular configuration. Specific KRATON® block copolymers include those sold under the brand names G 1652, G 1657, G 1730, MD6673, and MD6973. Various suitable styrenic block copolymers are described in U.S. Pat. Nos. 4,663,220, 4,323,534, 4,834,738, 5,093,422 and 5,304,599, which are hereby incorporated in their entirety by reference thereto for all purposes. Other commercially available block copolymers include the S-EP-S elastomeric copolymers available from Kuraray Company, Ltd. of Okayama, Japan, under the trade designation SEPTON®. Still other suitable copolymers include the S-1-S and S-B-S elastomeric copolymers available from Dexco Polymers of Houston, Tex. under the trade designation VECTOR®. Also suitable are polymers composed of an A-B-A-B tetrablock copolymer, such as discussed in U.S. Pat. No. 5,332,613 to Taylor, et al., which is incorporated herein in its entirety by reference thereto for all purposes. An example of such a tetrablock copolymer is a styrene-poly(ethylene-propylene)-styrene-poly(ethylene-propylene) (“S-EP-S-EP”) block copolymer.

Of course, other thermoplastic elastomeric polymers may also be used to form the film, either alone or in conjunction with the block copolymers. Semi-crystalline polyolefins, for example, may be employed that have or are capable of exhibiting a substantially regular structure. Exemplary semi-crystalline polyolefins include polyethylene, polypropylene, blends and copolymers thereof. In one particular embodiment, a polyethylene is employed that is a copolymer of ethylene and an α-olefin, such as a C₃-C₂₀ α-olefin or C₃-C₁₂ α-olefin. Suitable α-olefins may be linear or branched (e.g., one or more C₁-C₃ alkyl branches, or an aryl group). Specific examples include 1-butene; 3-methyl-1-butene; 3,3-dimethyl-1-butene; 1-pentene; 1-pentene with one or more methyl, ethyl or propyl substituents; 1-hexene with one or more methyl, ethyl or propyl substituents; 1-heptene with one or more methyl, ethyl or propyl substituents; 1-octene with one or more methyl, ethyl or propyl substituents; 1-nonene with one or more methyl, ethyl or propyl substituents; ethyl, methyl or dimethyl-substituted 1-decene; 1-dodecene; and styrene. Particularly desired α-olefin comonomers are 1-butene, 1-hexene and 1-octene. The ethylene content of such copolymers may be from about 60 mole % to about 99 mole %, in some embodiments from about 80 mole % to about 98.5 mole %, and in some embodiments, from about 87 mole % to about 97.5 mole %. The α-olefin content may likewise range from about 1 mole % to about 40 mole %, in some embodiments from about 1.5 mole % to about 15 mole %, and in some embodiments, from about 2.5 mole % to about 13 mole %.

Particularly suitable polyethylene copolymers are those that are “linear” or “substantially linear.” The term “substantially linear” means that, in addition to the short chain branches attributable to comonomer incorporation, the ethylene polymer also contains long chain branches in that the polymer backbone. “Long chain branching” refers to a chain length of at least 6 carbons. Each long chain branch may have the same comonomer distribution as the polymer backbone and be as long as the polymer backbone to which it is attached. Preferred substantially linear polymers are substituted with from 0.01 long chain branch per 1000 carbons to 1 long chain branch per 1000 carbons, and in some embodiments, from 0.05 long chain branch per 1000 carbons to 1 long chain branch per 1000 carbons. In contrast to the term “substantially linear”, the term “linear” means that the polymer lacks measurable or demonstrable long chain branches. That is, the polymer is substituted with an average of less than 0.01 long chain branch per 1000 carbons.

The density of a linear ethylene/α-olefin copolymer is a function of both the length and amount of the α-olefin. That is, the greater the length of the α-olefin and the greater the amount of α-olefin present, the lower the density of the copolymer. Although not necessarily required, linear polyethylene “plastomers” are particularly desirable in that the content of α-olefin short chain branching content is such that the ethylene copolymer exhibits both plastic and elastomeric characteristics—i.e., a “plastomer.” Because polymerization with α-olefin comonomers decreases crystallinity and density, the resulting plastomer normally has a density lower than that of polyethylene thermoplastic polymers (e.g., LLDPE), but approaching and/or overlapping that of an elastomer. For example, the density of the polyethylene plastomer may be 0.91 grams per cubic centimeter (g/cm³) or less, in some embodiments, from 0.85 to 0.88 g/cm³, and in some embodiments, from 0.85 g/cm³ to 0.87 g/cm³. Despite having a density similar to elastomers, plastomers generally exhibit a higher degree of crystallinity, are relatively non-tacky, and may be formed into pellets that are non-adhesive and relatively free flowing.

Preferred polyethylenes for use in the present invention are ethylene-based copolymer plastomers available under the designation EXACT™ from ExxonMobil Chemical Company of Houston, Tex. Other suitable polyethylene plastomers are available under the designation ENGAGE™ and AFFINITY™ from Dow Chemical Company of Midland, Mich. Still other suitable ethylene polymers are available from The Dow Chemical Company under the designations DOWLEX™ (LLDPE) and ATTANE™ (ULDPE). Other suitable ethylene polymers are described in U.S. Pat. No. 4,937,299 to Ewen et al.; U.S. Pat. No. 5,218,071 to Tsutsui et al.; U.S. Pat. No. 5,272,236 to Lai, et al.; and U.S. Pat. No. 5,278,272 to Lai, et al., which are incorporated herein in their entirety by reference thereto for all purposes.

Of course, the present invention is by no means limited to the use of ethylene polymers. For instance, propylene plastomers may also be suitable for use in the film. Suitable plastomeric propylene polymers may include, for instance, copolymers or terpolymers of propylene include copolymers of propylene with an α-olefin (e.g., C₃-C₂₀), such as ethylene, 1-butene, 2-butene, the various pentene isomers, 1-hexene, 1-octene, 1-nonene, 1-decene, 1-unidecene, 1-dodecene, 4-methyl-1-pentene, 4-methyl-1-hexene, 5-methyl-1-hexene, vinylcyclohexene, styrene, etc. The comonomer content of the propylene polymer may be about 35 wt. % or less, in some embodiments from about 1 wt. % to about 20 wt. %, and in some embodiments, from about 2 wt. % to about 10 wt. %. Preferably, the density of the polypropylene (e.g., propylene/1-olefin copolymer) may be 0.91 grams per cubic centimeter (g/cm³) or less, in some embodiments, from 0.85 to 0.88 g/cm³, and in some embodiments, from 0.85 g/cm³ to 0.87 g/cm³. Suitable propylene polymers are commercially available under the designations VISTAMAXX™ from ExxonMobil Chemical Co. of Houston, Tex.; FINA™ (e.g., 8573) from Atofina Chemicals of Feluy, Belgium; TAFMER™ available from Mitsui Petrochemical Industries; and VERSIFY™ available from Dow Chemical Co. of Midland, Mich. Other examples of suitable propylene polymers are described in U.S. Pat. No. 6,500,563 to Datta, et al.; U.S. Pat. No. 5,539,056 to Yang, et al.; and U.S. Pat. No. 5,596,052 to Resconi, et al., which are incorporated herein in their entirety by reference thereto for all purposes.

Any of a variety of known techniques may generally be employed to form the semi-crystalline polyolefins. For instance, olefin polymers may be formed using a free radical or a coordination catalyst (e.g., Ziegler-Natta). Preferably, the olefin polymer is formed from a single-site coordination catalyst, such as a metallocene catalyst. Such a catalyst system produces ethylene copolymers in which the comonomer is randomly distributed within a molecular chain and uniformly distributed across the different molecular weight fractions. Metallocene-catalyzed polyolefins are described, for instance, in U.S. Pat. No. 5,571,619 to McAlpin et al.; U.S. Pat. No. 5,322,728 to Davis et al.; U.S. Pat. No. 5,472,775 to Obijeski et al.; U.S. Pat. No. 5,272,236 to Lai et al.; and U.S. Pat. No. 6,090,325 to Wheat, et al., which are incorporated herein in their entirety by reference thereto for all purposes. Examples of metallocene catalysts include bis(n-butylcyclopentadienyl)titanium dichloride, bis(n-butylcyclopentadienyl)zirconium dichloride, bis(cyclopentadienyl)scandium chloride, bis(indenyl)zirconium dichloride, bis(methylcyclopentadienyl)titanium dichloride, bis(methylcyclopentadienyl)zirconium dichloride, cobaltocene, cyclopentadienyltitanium trichloride, ferrocene, hafnocene dichloride, isopropyl(cyclopentadienyl,-1-flourenyl)zirconium dichloride, molybdocene dichloride, nickelocene, niobocene dichloride, ruthenocene, titanocene dichloride, zirconocene chloride hydride, zirconocene dichloride, and so forth. Polymers made using metallocene catalysts typically have a narrow molecular weight range. For instance, metallocene-catalyzed polymers may have polydispersity numbers (M_(w)/M_(n)) of below 4, controlled short chain branching distribution, and controlled isotacticity.

The melt flow index (MI) of the semi-crystalline polyolefins may generally vary, but is typically in the range of about 0.1 grams per 10 minutes to about 100 grams per 10 minutes, in some embodiments from about 0.5 grams per 10 minutes to about 30 grams per 10 minutes, and in some embodiments, about 1 to about 10 grams per 10 minutes, determined at 190° C. The melt flow index is the weight of the polymer (in grams) that may be forced through an extrusion rheometer orifice (0.0825-inch diameter) when subjected to a force of 5000 grams in 10 minutes at 190° C., and may be determined in accordance with ASTM Test Method D1238-E.

Of course, besides elastomeric polymers, generally inelastic thermoplastic polymers may also be used so long as they do not adversely affect the elasticity of the composite. For example, the thermoplastic composition may contain other polyolefins (e.g., polypropylene, polyethylene, etc.). In one embodiment, the thermoplastic composition may contain an additional propylene polymer, such as homopolypropylene or a copolymer of propylene. The additional propylene polymer may, for instance, be formed from a substantially isotactic polypropylene homopolymer or a copolymer containing equal to or less than about 10 wt. % of other monomer, i.e., at least about 90% by weight propylene. Such a polypropylene may be present in the form of a graft, random, or block copolymer and may be predominantly crystalline in that it has a sharp melting point above about 110° C., in some embodiments about above 115° C., and in some embodiments, above about 130° C. Examples of such additional polypropylenes are described in U.S. Pat. No. 6,992,159 to Datta, et al., which is incorporated herein in its entirety by reference thereto for all purposes.

The elastic film may also contain other components as is known in the art. In one embodiment, for example, the elastic film contains a filler. Fillers are particulates or other forms of material that may be added to the film polymer extrusion blend and that will not chemically interfere with the extruded film, but which may be uniformly dispersed throughout the film. Fillers may serve a variety of purposes, including enhancing film opacity and/or breathability (i.e., vapor-permeable and substantially liquid-impermeable). For instance, filled films may be made breathable by stretching, which causes the polymer to break away from the filler and create microporous passageways. Breathable microporous elastic films are described, for example, in U.S. Pat. Nos. 5,997,981; 6,015,764; and 6,111,163 to McCormack, et al.; U.S. Pat. No. 5,932,497 to Morman, et al.; U.S. Pat. No. 6,461,457 to Taylor, et al., which are incorporated herein in their entirety by reference thereto for all purposes. Examples of suitable fillers include, but are not limited to, calcium carbonate, various kinds of clay, silica, alumina, barium carbonate, sodium carbonate, magnesium carbonate, talc, barium sulfate, magnesium sulfate, aluminum sulfate, titanium dioxide, zeolites, cellulose-type powders, kaolin, mica, carbon, calcium oxide, magnesium oxide, aluminum hydroxide, pulp powder, wood powder, cellulose derivatives, chitin and chitin derivatives. In certain cases, the filler content of the film may range from about 25 wt. % to about 75 wt. %, in some embodiments, from about 30 wt. % to about 70 wt. %, and in some embodiments, from about 40 wt. % to about 60 wt. % of the film.

Other additives may also be incorporated into the film, such as melt stabilizers, crosslinking catalysts, pro-rad additives, processing stabilizers, heat stabilizers, light stabilizers, antioxidants, heat aging stabilizers, whitening agents, antiblocking agents, bonding agents, tackifiers, viscosity modifiers, etc. Examples of suitable tackifier resins may include, for instance, hydrogenated hydrocarbon resins. REGALREZ™ hydrocarbon resins are examples of such hydrogenated hydrocarbon resins, and are available from Eastman Chemical. Other tackifiers are available from ExxonMobil under the ESCOREZ™ designation. Viscosity modifiers may also be employed, such as polyethylene wax (e.g., EPOLENE™ C-10 from Eastman Chemical). Phosphite stabilizers (e.g., IRGAFOS available from Ciba Specialty Chemicals of Terrytown, N.Y. and DOVERPHOS available from Dover Chemical Corp. of Dover, Ohio) are exemplary melt stabilizers. In addition, hindered amine stabilizers (e.g., CHIMASSORB available from Ciba Specialty Chemicals) are exemplary heat and light stabilizers. Further, hindered phenols are commonly used as an antioxidant in the production of films. Some suitable hindered phenols include those available from Ciba Specialty Chemicals of under the trade name “Irganox®”, such as Irganox® 1076, 1010, or E 201. Moreover, bonding agents may also be added to the film to facilitate bonding of the film to additional materials (e.g., nonwoven web). Typically, such additives (e.g., tackifier, antioxidant, stabilizer, etc.) are each present in an amount from about 0.001 wt. % to about 25 wt. %, in some embodiments, from about 0.005 wt. % to about 20 wt. %, and in some embodiments, from 0.01 wt. % to about 15 wt. % of the film.

The elastic film of the present invention may be mono- or multi-layered. Multi-layered films may be prepared by co-extrusion or any other conventional layering technique. When employed, the multi-layered film typically contains at least one thermoplastic layer and at least one elastic layer. The thermoplastic layer may be employed to provide strength and integrity to the resulting composite, while the elastic layer may be employed to provide elasticity and sufficient tack for adhering to the nonwoven facing. In one particular embodiment of the present invention, the film includes at least one thermoplastic layer positioned between at least two elastic layers. In this manner, the thermoplastic layer does not substantially contact the nonwoven facing and is thus able to avoid substantial damage during lamination. In such embodiments, one or more elastic layers are generally formed from an elastomeric composition, such as described above, to provide the desired degree of elasticity in the film. To impart the desired elastic properties to the film, elastomers typically constitute about 55 wt. % or more, in some embodiments about 60 wt. % or more, and in some embodiments, from about 65 wt. % to 100 wt. % of the polymer content of the elastomeric composition used to form the elastic layer(s). In fact, in certain embodiments, the elastic layer(s) may be generally free of polymers that are inelastic. For example, such inelastic polymers may constitute about 15 wt. % or less, in some embodiments about 10 wt. % or less, and in some embodiments, about 5 wt. % or less of the polymer content of the elastomeric composition.

Although the thermoplastic layer(s) may possess some degree of elasticity, such layers are generally formed from a thermoplastic composition that is less elastic than the elastic layer(s) to ensure that the strength of the film is sufficiently enhanced. For example, one or more elastic layers may be formed primarily from substantially amorphous elastomers (e.g., styrene-olefin copolymers) and one or more thermoplastic layers may be formed from polyolefin plastomers (e.g., single-site catalyzed ethylene or propylene copolymers), which are described in more detail above. Although possessing some elasticity, such polyolefins are generally less elastic than substantially amorphous elastomers. Of course, the thermoplastic layer(s) may contain generally inelastic polymers, such as conventional polyolefins, e.g., polyethylene (low density polyethylene (“LDPE”), Ziegler-Natta catalyzed linear low density polyethylene (“LLDPE”), etc.), polypropylene, polybutylene, etc.; polytetrafluoroethylene; polyesters, e.g., polyethylene terephthalate, etc.; polyvinyl acetate; polyvinyl chloride acetate; polyvinyl butyral; acrylic resins, e.g., polyacrylate, polymethylacrylate, polymethylmethacrylate, etc.; polyamides, e.g., nylon; polyvinyl chloride; polyvinylidene chloride; polystyrene; polyvinyl alcohol; polyurethanes; polylactic acid; copolymers and mixtures thereof; and so forth. In certain embodiments, polyolefins (e.g., conventional and/or plastomers) are employed and constitute about 55 wt. % or more, in some embodiments about 60 wt. % or more, and in some embodiments, from about 65 wt. % to 100 wt. % of the polymer content of the thermoplastic composition used to form the thermoplastic layer(s).

The thickness of the thermoplastic and elastic layers is generally selected so as to achieve an appropriate balance between film elasticity and strength. For instance, the thickness of an elastic layer is typically from about 20 to about 200 micrometers, in some embodiments from about 25 to about 175 micrometers, and in some embodiments, from about 30 to about 150 micrometers. The elastic layer(s) may also constitute from about 70% to about 99.5% of the total thickness of the film, and in some embodiments from about 80% to about 99% of the total thickness of the film. On the other hand, the thickness of a thermoplastic layer(s) is typically from about 0.5 to about 20 micrometers, in some embodiments from about 1 to about 15 micrometers, and in some embodiments, from about 2 to about 12 micrometers. The elastic layer(s) may also constitute from about 0.5% to about 30% of the total thickness of the film, and in some embodiments from about 1% to about 20% of the total thickness of the film. The film may also have a total thickness of from about 20 to about 250 micrometers, in some embodiments, from about 25 to about 225 micrometers, and in some embodiments, from about 30 to about 200 micrometers.

Regardless of the particular film content, the film and/or the materials used to form the film may also be subjected to one or more additional processing steps. In one embodiment, for example, an elastomeric polymer employed in the film is crosslinked, before, after, and/or during lamination to the nonwoven facing, to provide the film with enhanced elastic characteristics. Crosslinking may be induced by subjecting the polymer to electromagnetic radiation, such as ultraviolet light, electron beam radiation, natural and artificial radio isotopes (e.g., α, β, and γ rays), x-rays, neutron beams, positively-charged beams, laser beams, and so forth. The wavelength (“λ”) of the electromagnetic radiation may be about 1000 nanometers or less, in some embodiments about 100 nanometers or less, and in some embodiments, about 1 nanometer or less. Electron beam radiation, for instance, typically has a wavelength of about 1 nanometer or less. The total dosage employed (in one or multiple steps) may likewise range from about 1 megarad (Mrad) to about 30 Mrads, in some embodiments, from about 3 Mrads to about 25 Mrads, and in some embodiments, from about 5 to about 15 Mrads. In addition, the energy level may range from about 0.05 megaelectron volts (MeV) to about 600 MeV. Upon crosslinking, a three-dimensional crosslinked network may be formed that provides the material with additional elasticity in the machine direction, cross-machine direction, or both.

II. Second Laminate

A. Nonwoven Facing

The nonwoven facing of the second laminate may include any suitable nonwoven material, such as a meltblown web, spunbond web, bonded carded web, wetlaid web, airlaid web, coform web, hydraulically entangled web, etc., as well as combinations of the foregoing. In one particular embodiment, the facing may be a bonded carded facing. Fibers of any desired length may be employed in the bonded carding facing, such as staple fibers, continuous fibers, etc. For example, staple fibers may be used that have a fiber length in the range of from about 1 to about 150 millimeters, in some embodiments from about 5 to about 50 millimeters, in some embodiments from about 10 to about 40 millimeters, and in some embodiments, from about 10 to about 25 millimeters. Such fibers may be formed into a carded web by placing bales of the fibers into a picker that separates the fibers. Next, the fibers are sent through a combing or carding unit that further breaks apart and aligns the fibers in the machine direction so as to form a machine direction-oriented fibrous nonwoven web. The carded web may then be lightly bonded in a manner such as described above.

Although not required, the facing of the second laminate may also be lightweight and of low strength. For example, the basis weight of the facing may range from about 1 to about 45 grams per square meter, in some embodiments from about 2 to about 30 grams per square meter, and in some embodiments, from about 3 to about 20 grams per square meter. The facing may also have a peak load in the cross-machine direction (“CD”) of about 350 grams-force per inch (width) or less, in some embodiments about 300 grams-force per inch or less, in some embodiments from about 50 to about 300 grams-force per inch, in some embodiments from about 60 to about 250 grams-force per inch, and in some embodiments, from about 75 to about 200 grams-force per inch. If desired, the nonwoven facing may also have a low strength in the machine direction (“MD”), such as a peak load in the machine direction of about 3000 grams-force per inch (width) or less, in some embodiments about 2500 grams-force per inch or less, in some embodiments from about 50 to about 2000 grams-force per inch, and in some embodiments, from about 100 to about 1500 grams-force per inch.

As described above, the nonwoven facing of the second laminate may also be stretched in the machine and/or cross-machine directions prior to lamination to the film of the present invention, as well as subjected to other known processing steps, such as aperturing, heat treatments, etc.

B. Thermoplastic Film

The thermoplastic film of the second laminate is formed from one or more thermoplastic polymers. If desired, the thermoplastic polymers may be elastomers, such as described above, such that the film possesses a certain degree of elasticity. Such elastomers may be the same or different than the elastomers used in the elastic film of the first laminate. In one embodiment for example, the elastic film may be formed from a composition that includes substantially amorphous elastomers (e.g., styrene-olefin copolymers) and the thermoplastic film may be formed from a composition that includes polyolefin plastomers (e.g., single-site catalyzed ethylene or propylene copolymers), which are described in more detail above. Although possessing some elasticity, such polyolefins are generally less elastic than substantially amorphous elastomers. Of course, the thermoplastic film may also contain generally inelastic polymers as described above. In fact, polyolefins (e.g., conventional and/or plastomers) may constitute about 55 wt. % or more, in some embodiments about 60 wt. % or more, and in some embodiments, from about 65 wt. % to 100 wt. % of the polymer content of the composition used to form the thermoplastic film. The thermoplastic film may also have a mono-layered or multi-layered structure, such as described above.

Regardless of the content, the basis weight of the elastic film and thermoplastic film are generally selected so as to achieve an appropriate balance between film elasticity and strength. For instance, the basis weight of the elastic film may range from about 1 to about 45 grams per square meter, in some embodiments from about 2 to about 30 grams per square meter, and in some embodiments, from about 5 to about 20 grams per square meter. The basis weight of the thermoplastic film may likewise range from about 1 to about 45 grams per square meter, in some embodiments from about 2 to about 30 grams per square meter, and in some embodiments, from about 5 to about 20 grams per square meter. The film may also have a total thickness of from about 1 to about 100 micrometers, in some embodiments, from about 10 to about 80 micrometers, and in some embodiments, from about 20 to about 60 micrometers.

III. Composite Formation

To enhance the durability and stability, the first laminate is typically formed by directly extruding the elastomeric composition onto a surface of the nonwoven facing. This allows for an enhanced degree of contact between the elastomeric composition and fibers of the nonwoven facing, which further increases the ability of the meltblown fibers to bond to the elastomeric composition. In this manner, a sufficient degree of bonding is achieved without requiring the application of a substantial amount of heat and pressure used in conventional calender bonding processes, which can damage the low strength nonwoven facing. If desired, lamination may be facilitated through the use of a variety of techniques, such as adhesives, suctional forces, etc. In one embodiment, for example, the film is biased toward the facing during lamination with a suctional force. The second laminate may be formed using the same technique or a different technique depending on the desired application. Regardless, the first and second laminates are positioned so that the elastic and thermoplastic films are in a face-to-face relationship. Through selective control over the polymer content and thickness, the present inventors have discovered that the elastic and thermoplastic films may be readily joined together under light pressure, even at ambient temperature conditions. This avoids the application of a substantial amount of heat used in conventional calender bonding processes, which can otherwise damage the film, and also minimize the need for costly adhesives.

Various embodiments of the lamination technique of the present invention will now be described in greater detail. Referring to FIG. 1, for instance, one embodiment of a method for forming a composite is shown. In this embodiment, a first laminate 310 is formed from a meltblown facing 130 made in-line by feeding raw materials (e.g., polypropylene) into an extruder 108 from a hopper 106, and thereafter supplying the extruded composition to a meltblown die 109. As the polymer exits the die 109 at an orifice (not shown), high pressure fluid (e.g., heated air) attenuates and spreads the polymer stream into microfibers 111 that are randomly deposited onto a surface of a roll 170 to form a meltblown facing 130. It should be understood that the meltblown facing 130 may also be formed on a separate foraminous surface (e.g., wire, belt, fabric, etc.) that subsequently traverses over the roll 170. Further, it should be understood that the meltblown facing 130 may simply be unwound from a supply roll rather than formed in-line.

In the embodiment shown in FIG. 1, an elastic film is also formed that contains a single thermoplastic layer 123 and a single elastic layer 121. The raw materials of the elastic layer 121 may be added to a hopper 112 of an extruder 114 and the raw materials of the thermoplastic layer 123 may be added to a hopper 122 of an extruder 124. The materials are dispersively mixed and compounded under at an elevated temperature within the extruders 114 and 124. The selection of an appropriate melt processing temperature will help melt and/soften the elastomeric polymer(s) of the film. The softened elastomeric polymer(s) may then flow and become fused to the meltblown facing, thereby forming an integral laminate structure. Furthermore, because the elastomeric polymer(s) may physically entrap or adhere to the fibers at the bond sites, adequate bond formation may be achieved without requiring substantial softening of the polymer(s) used to form the facing. Of course, it should be understood that the temperature of the facing may be above its softening point in certain embodiments.

Within the extruder 114, for example, melt blending of the elastomeric composition may occur at a temperature of from about 50° C. to about 300° C., in some embodiments from about 60° C. to about 275° C., and in some embodiments, from about 70° C. to about 260° C. Melt blending of the thermoplastic composition may occur within the extruder 124 at a temperature that is the same, lower, or higher than employed for the elastomeric composition. For example, melt blending of the thermoplastic composition may in some instances occur at a temperature of from about 50° C. to about 250° C., in some embodiments from about 60° C. to about 225° C., and in some embodiments, from about 70° C. to about 200° C. The apparent shear rate during melt blending may range from about 100 seconds⁻¹ to about 10,000 seconds⁻¹, in some embodiments from about 500 seconds⁻¹ to about 5000 seconds⁻¹, and in some embodiments, from about 800 seconds⁻¹ to about 1200 seconds⁻¹. The apparent shear rate is equal to 4Q/πR³, where Q is the volumetric flow rate (“m³/s”) of the polymer melt and R is the radius (“m”) of the capillary (e.g., extruder die) through which the melted polymer flows.

Any known technique may be used to form a film from the compounded material, including casting, flat die extruding, etc. In the particular embodiment of FIG. 1, for example, the elastic and thermoplastic layers are “cast” onto the meltblown facing 130, which is positioned on the roll 170, as is known in the art. A cast elastic film 241 is thus formed on the facing 130 such that the elastic layer 121 is positioned directly adjacent to the facing 130. To enhance bonding between the elastic film 241 and the facing 130, a suctional force is applied to bias the elastic film 241 against an upper surface of the meltblown facing 130. This may be accomplished in a variety of ways (e.g., vacuum slots, shoes, rolls, etc.) and at a variety of locations throughout the composite-forming process. In the embodiment shown in FIG. 1, for example, the roll 170 on which the elastic film 241 is cast is a vacuum roll capable of applying the desired suctional force. The amount of suctional force may be selectively controlled to enhance bonding without significantly deteriorating the integrity of the low strength facing. For example, pneumatic vacuum pressure may be employed to apply the suctional force that is about 0.25 kilopascals or more, in some embodiments about from about 0.3 to about 5 kilopascals, and in some embodiments, from about 0.5 to about 2 kilopascals. Such vacuum-assisted lamination allows for the formation of a strong composite without the need for a substantial amount of heat and pressure normally used in calender lamination methods that could otherwise diminish the integrity of the nonwoven facing. In fact, the roll 170 on which the elastic film 241 is formed may even be kept at ambient temperature if so desired.

A second laminate 320 is also formed from a nonwoven facing 131 made in-line or originating from a supply roll (e.g., roll 62). The nonwoven facing 131 may include any nonwoven material, such as a meltblown web, spunbond web, bonded carded web, etc. The second laminate 320 also contains a thermoplastic film 242 positioned adjacent to the nonwoven facing 131. In the illustrated embodiment, a vacuum lamination technique is employed. More specifically, the raw materials of a elastic layer 221 are added to a hopper 212 of an extruder 214 and the raw materials of a thermoplastic layer 223 are added to a hopper 222 of an extruder 224. The materials are then co-extruded onto the nonwoven facing 131 to form the thermoplastic film 242. A suctional force is also applied to bias the thermoplastic film 242 against an upper surface of the nonwoven facing 131 to form the second laminate 320.

Once formed, the first laminate 310 and second laminate 320 are then joined together to form a composite 180. Any of a variety of techniques may be employed to join the laminates together. In the embodiment shown in FIG. 1, for example, the laminates 310 and 320 are joined together via a patterned bonding technique (e.g., point bonding, ultrasonic bonding, etc.) in which the materials are supplied to a nip defined by at least one patterned roll (e.g., rolls 190). Point bonding, for instance, typically employs a nip formed between two rolls, at least one of which is patterned. Ultrasonic bonding, on the other hand, typically employs a nip formed between a sonic horn and a patterned roll. Regardless of the technique chosen, the patterned roll contains a plurality of bonding elements to concurrently bond the films of each laminate. The present inventors have discovered that the pressure exerted by rolls (“nip pressure”) during pattern bonding may be relatively low and still achieve a considerable degree of peel strength. For example the nip pressure may range from about 1 to about 200 pounds per linear inch, in some embodiments from about 2 to about 100 pounds per linear inch, and in some embodiments, from about 5 to about 75 pounds per linear inch. The present inventors have also discovered that the films of each laminate can readily bond together at relatively low temperatures. In fact, the rolls may even be kept at ambient temperature. For example, the rolls desirably have a surface temperature of from about 5° C. to about 60° C., in some embodiments from about 10° C. to about 55° C., and in some embodiments, from about 15° C. to about 50° C. Of course, it should be understood that higher nip pressures and/or temperatures may be employed if so desired. Also, the residence time of the materials may influence the particular bonding parameters employed.

Various processing and/or finishing steps known in the art, such as slitting, stretching, etc., may also be performed without departing from the spirit and scope of the invention. For instance, the composite may optionally be mechanically stretched in the cross-machine and/or machine directions to enhance extensibility. In the embodiment shown in FIG. 1, for example, the rolls 190 may possess grooves in the CD and/or MD directions that incrementally stretch the composite 180 in the CD and/or MD direction and also join together the laminates 310 and 320. Alternatively, the rolls 190 may join together the laminates 310 and 320 and separate grooved rolls (not shown) may be used to incrementally stretch the composite 180. Grooved satellite/anvil roll arrangements are described in U.S. Patent Application Publication Nos. 2004/0110442 to Rhim, et al. and 2006/0151914 to Gerndt, et al., which are incorporated herein in their entirety by reference thereto for all purposes.

FIGS. 4-5 further illustrate the manner in which groove rolls may incrementally stretch the composite. As shown, for example, satellite rolls 382 may engage an anvil roll 384, each of which include a plurality of ridges 383 defining a plurality of grooves 385 positioned across the grooved rolls in the cross-machine direction. The grooves 385 are generally oriented perpendicular to the direction of stretch of the material. In other words, the grooves 385 are oriented in the machine direction to stretch the composite in the cross-machine direction. The grooves 385 may likewise be oriented in the cross-machine direction to stretch the composite in the machine direction. The ridges 383 of satellite roll 382 intermesh with the grooves 385 of anvil roll 384, and the grooves 385 of satellite roll 382 intermesh with the ridges 383 of anvil roll 384.

The dimensions and parameters of the grooves 385 and ridges 383 may have a substantial effect on the degree of extensibility provided by the rolls 382 and 384. For example, the number of grooves 385 contained on a roll may generally range from about 3 and 15 grooves per inch, in some embodiments from about 5 and 12 grooves per inch, and in some embodiments, from about 5 and 10 grooves per inch. The grooves 385 may also have a certain depth “D”, which generally ranges from about 0.25 to about 1.0 centimeter, and in some embodiments, from about 0.4 to about 0.6 centimeters. In addition, the peak-to-peak distance “P” between the grooves 385 is typically from about 0.1 to about 0.9 centimeters, and in some embodiments, from about 0.2 to about 0.5 centimeters. Also, the groove roll engagement distance “E” between the grooves 385 and ridges 383 may be from about 0.05 to about 0.8 centimeters, in some embodiments from about 0.1 to about 0.7 centimeters, and in some embodiments, from about 0.15 to about 0.6 centimeters. Regardless, the composite 180 (FIG. 1) may be stretched in one or more directions to a dimension (e.g., length or width) that is from about 100% to about 750%, in some embodiments by from about 125% to about 500%, and in some embodiments, from about 150% to about 400% of its initial dimension prior to stretching. If desired, heat may be applied to the composite just prior to or during the application of incremental stretch to cause it to relax somewhat and ease extension. Heat may be applied by any suitable method known in the art, such as heated air, infrared heaters, heated nipped rolls, or partial wrapping of the laminate around one or more heated rolls or steam canisters, etc. Heat may also be applied to the grooved rolls themselves. It should also be understood that other grooved roll arrangement are equally suitable, such as two grooved rolls positioned immediately adjacent to one another.

Besides the above-described grooved rolls, other techniques may also be used to mechanically stretch the composite in one or more directions. For example, the composite may be passed through a tenter frame that stretches the composite. Such tenter frames are well known in the art and described, for instance, in U.S. Patent Application Publication No. 2004/0121687 to Morman, et al. The composite may also be necked. Suitable techniques necking techniques are described in U.S. Pat. Nos. 5,336,545, 5,226,992, 4,981,747 and 4,965,122 to Morman, as well as U.S. Patent Application Publication No. 2004/0121687 to Morman, et al., all of which are incorporated herein in their entirety by reference thereto for all purposes.

Referring again to FIG. 1, the composite 180, upon formation, may then be slit, wound, and stored on a take-up roll 195. The composite 180 may be allowed to retract in the machine direction prior to and/or during winding on to the take-up roll 195. This may be achieved by using a slower linear velocity for the roll 195. Alternatively, the composite 180 may be wound onto the roll 195 under tension.

The resulting composite thus contains an elastic film and thermoplastic film positioned in a face-to-face relationship and bonded to each other. The elastic film is also laminated to the first nonwoven facing and the thermoplastic film is laminated to the second nonwoven facing. Referring to FIG. 2, for example, one embodiment of a composite 500 is shown that includes a first laminate 520 and a second laminate 530. The first laminate 520 is formed from a first nonwoven facing 522 and elastic film 524 and the second laminate 530 is formed from a second nonwoven facing 532 and a thermoplastic film 534. In this embodiment, an upper surface 551 of the elastic film 524 is positioned adjacent and bonded to a lower surface 553 of the thermoplastic film 534. Such a composite structure provides a unique combination of strength and elasticity in a cost-effective manner. For example, the use of a lightweight nonwoven facing enhances flexibility and reduces costs, while the use of separately bonded films allows for the production of a strong composite using techniques (e.g., vacuum lamination, light pattern bonding, etc.) that do not generally damage the integrity of the facings or films.

The present inventors have discovered that the resulting composite possesses a high degree of extensibility and elastic recovery. That is, the composite may exhibit an elongation at peak load (“peak elongation”) in the cross-machine direction, machine direction, or both of about 75% or more, in some embodiments about 100% or more, and in some embodiments, from about 150% to about 500%. The composite may also be elastic in that it is extensible in at least one direction upon application of the stretching force and, upon release of the stretching force, contracts/returns to approximately its original dimension. For example, a stretched material may have a stretched length that is at least 50% greater than its relaxed unstretched length, and which will recover to within at least 50% of its stretched length upon release of the stretching force. A hypothetical example would be a one (1) inch sample of a material that is stretchable to at least 1.50 inches and which, upon release of the stretching force, will recover to a length of not more than 1.25 inches. Desirably, the composite contracts or recovers at least 50%, and even more desirably, at least 80% of the stretched length.

The composite may also possess a high degree of strength in the machine direction and/or cross-machine direction. For example, the CD peak load of the composite may be at least about 1000 grams-force per inch (“g_(f)/in”), in some embodiments from about 1100 to about 3000 g_(f)/in, and in some embodiments, from about 1200 to about 2500 g_(f)/in. Likewise, the MD peak load may be at least about 1500 grams-force per inch (“g_(f)/in”), in some embodiments from about 1500 to about 6000 g_(f)/in, and in some embodiments, from about 2000 to about 5000 g_(f)/in.

IV. Articles

The composite of the present invention may be used in a wide variety of applications. As noted above, for example, the composite may be used in an absorbent article. An “absorbent article” generally refers to any article capable of absorbing water or other fluids. Examples of some absorbent articles include, but are not limited to, personal care absorbent articles, such as diapers, training pants, absorbent underpants, incontinence articles, feminine hygiene products (e.g., sanitary napkins), swim wear, baby wipes, and so forth; medical absorbent articles, such as garments, fenestration materials, underpads, bedpads, bandages, absorbent drapes, and medical wipes; food service wipers; clothing articles; and so forth. Materials and processes suitable for forming such absorbent articles are well known to those skilled in the art. Typically, absorbent articles include a substantially liquid-impermeable layer (e.g., outer cover), a liquid-permeable layer (e.g., bodyside liner, surge layer, etc.), and an absorbent core. In one particular embodiment, the composite of the present invention may be used in providing elastic waist, leg cuff/gasketing, stretchable ear, side panel or stretchable outer cover applications.

Various embodiments of an absorbent article that may be formed according to the present invention will now be described in more detail. Referring to FIG. 3, for example, one embodiment of a disposable diaper 450 is shown that generally defines a front waist section 455, a rear waist section 460, and an intermediate section 465 that interconnects the front and rear waist sections. The front and rear waist sections 455 and 460 include the general portions of the diaper which are constructed to extend substantially over the wearer's front and rear abdominal regions, respectively, during use. The intermediate section 465 of the diaper includes the general portion of the diaper that is constructed to extend through the wearer's crotch region between the legs. Thus, the intermediate section 465 is an area where repeated liquid surges typically occur in the diaper.

The diaper 450 includes, without limitation, an outer cover, or backsheet 470, a liquid permeable bodyside liner, or topsheet, 475 positioned in facing relation with the backsheet 470, and an absorbent core body, or liquid retention structure, 480, such as an absorbent pad, which is located between the backsheet 470 and the topsheet 475. The backsheet 470 defines a length, or longitudinal direction 486, and a width, or lateral direction 485 which, in the illustrated embodiment, coincide with the length and width of the diaper 450. The liquid retention structure 480 generally has a length and width that are less than the length and width of the backsheet 470, respectively. Thus, marginal portions of the diaper 450, such as marginal sections of the backsheet 470 may extend past the terminal edges of the liquid retention structure 480. In the illustrated embodiments, for example, the backsheet 470 extends outwardly beyond the terminal marginal edges of the liquid retention structure 480 to form side margins and end margins of the diaper 450. The topsheet 475 is generally coextensive with the backsheet 470 but may optionally cover an area that is larger or smaller than the area of the backsheet 470, as desired.

To provide improved fit and to help reduce leakage of body exudates from the diaper 450, the diaper side margins and end margins may be elasticized with suitable elastic members, as further explained below. For example, as representatively illustrated in FIG. 3, the diaper 450 may include leg elastics 490 constructed to operably tension the side margins of the diaper 450 to provide elasticized leg bands which can closely fit around the legs of the wearer to reduce leakage and provide improved comfort and appearance. Waist elastics 495 are employed to elasticize the end margins of the diaper 450 to provide elasticized waistbands. The waist elastics 495 are configured to provide a resilient, comfortably close fit around the waist of the wearer. The elastic composite of the present invention is suitable for use as the leg elastics 490 and waist elastics 495. Exemplary of such materials are laminate sheets that either comprise or are adhered to the backsheet, such that elastic constrictive forces are imparted to the backsheet 470.

As is known, fastening means, such as hook and loop fasteners, may be employed to secure the diaper 450 on a wearer. Alternatively, other fastening means, such as buttons, pins, snaps, adhesive tape fasteners, cohesives, fabric-and-loop fasteners, or the like, may be employed. In the illustrated embodiment, the diaper 450 includes a pair of side panels 400 (or ears) to which the fasteners 402, indicated as the hook portion of a hook and loop fastener, are attached. Generally, the side panels 400 are attached to the side edges of the diaper in one of the waist sections 455, 460 and extend laterally outward therefrom. The side panels 400 may be elasticized or otherwise rendered elastomeric by use of the elastic composite of the present invention. Examples of absorbent articles that include elasticized side panels and selectively configured fastener tabs are described in PCT Patent Application WO 95/16425 to Roessler; U.S. Pat. No. 5,399,219 to Roessler et al.; U.S. Pat. No. 5,540,796 to Fries; and U.S. Pat. No. 5,595,618 to Fries, each of which is incorporated herein in its entirety by reference thereto for all purposes.

The diaper 450 may also include a surge management layer 405, located between the topsheet 475 and the liquid retention structure 480, to rapidly accept fluid exudates and distribute the fluid exudates to the liquid retention structure 480 within the diaper 450. The diaper 450 may further include a ventilation layer (not illustrated), also called a spacer, or spacer layer, located between the liquid retention structure 480 and the backsheet 470 to insulate the backsheet 470 from the liquid retention structure 480 to reduce the dampness of the garment at the exterior surface of a breathable outer cover, or backsheet, 470. Examples of suitable surge management layers 305 are described in U.S. Pat. No. 5,486,166 to Bishop and U.S. Pat. No. 5,490,846 to Ellis.

As representatively illustrated in FIG. 3, the disposable diaper 450 may also include a pair of containment flaps 410 which are configured to provide a barrier to the lateral flow of body exudates. The containment flaps 410 may be located along the laterally opposed side edges of the diaper adjacent the side edges of the liquid retention structure 480. Each containment flap 410 typically defines an unattached edge that is configured to maintain an upright, perpendicular configuration in at least the intermediate section 465 of the diaper 450 to form a seal against the wearer's body. The containment flaps 410 may extend longitudinally along the entire length of the liquid retention structure 480 or may only extend partially along the length of the liquid retention structure. When the containment flaps 410 are shorter in length than the liquid retention structure 480, the containment flaps 410 can be selectively positioned anywhere along the side edges of the diaper 450 in the intermediate section 465. Such containment flaps 410 are generally well known to those skilled in the art. For example, suitable constructions and arrangements for containment flaps 410 are described in U.S. Pat. No. 4,704,116 to Enloe.

The diaper 450 may be of various suitable shapes. For example, the diaper may have an overall rectangular shape, T-shape or an approximately hour-glass shape. In the shown embodiment, the diaper 450 has a generally I-shape. Other suitable components which may be incorporated on absorbent articles of the present invention may include waist flaps and the like which are generally known to those skilled in the art. Examples of diaper configurations suitable for use in connection with the elastic composite of the present invention that may include other components suitable for use on diapers are described in U.S. Pat. No. 4,798,603 to Meyer et al.; U.S. Pat. No. 5,176,668 to Bernardin; U.S. Pat. No. 5,176,672 to Bruemmer et al.; U.S. Pat. No. 5,192,606 to Proxmire et al.; and U.S. Pat. No. 5,509,915 to Hanson et al., which are incorporated herein in their entirety by reference thereto for all purposes.

The various regions and/or components of the diaper 450 may be assembled together using any known attachment mechanism, such as adhesive, ultrasonic, thermal bonds, etc. Suitable adhesives may include, for instance, hot melt adhesives, pressure-sensitive adhesives, and so forth. When utilized, the adhesive may be applied as a uniform layer, a patterned layer, a sprayed pattern, or any of separate lines, swirls or dots. In the illustrated embodiment, for example, the topsheet 475 and backsheet 470 may be assembled to each other and to the liquid retention structure 480 with lines of adhesive, such as a hot melt, pressure-sensitive adhesive. Similarly, other diaper components, such as the elastic members 490 and 495, fastening members 402, and surge layer 405 may be assembled into the article by employing the above-identified attachment mechanisms.

Although various configurations of a diaper have been described above, it should be understood that other diaper and absorbent article configurations are also included within the scope of the present invention. In addition, the present invention is by no means limited to diapers. In fact, several examples of absorbent articles are described in U.S. Pat. No. 5,649,916 to DiPalma, et al.; U.S. Pat. No. 6,110,158 to Kielpikowski; U.S. Pat. No. 6,663,611 to Blaney, et al., which are incorporated herein in their entirety by reference thereto for all purposes. Further, other examples of personal care products that may incorporate such materials are training pants (such as in side panel materials) and feminine care products. By way of illustration only, training pants suitable for use with the present invention and various materials and methods for constructing the training pants are disclosed in U.S. Pat. No. 6,761,711 to Fletcher et al.; U.S. Pat. No. 4,940,464 to Van Gompel et al.; U.S. Pat. No. 5,766,389 to Brandon et al.; and U.S. Pat. No. 6,645,190 to Olson et al., which are incorporated herein in their entirety by reference thereto for all purposes.

The present invention may be better understood with reference to the following examples.

Test Methods

Tensile Properties:

The strip tensile strength values were determined in substantial accordance with ASTM Standard D-5034. Specifically, a sample was cut or otherwise provided with size dimensions that measured 1 inch (25.4 millimeters) (width)×6 inches (152.4 millimeters) (length). A constant-rate-of-extension type of tensile tester was employed. The tensile testing system was a Sintech Tensile Tester, which is available from MTS Corp. of Eden Prairie, Minn. The tensile tester was equipped with TESTWORKS 4.08B software from MTS Corporation to support the testing. An appropriate load cell was selected so that the tested value fell within the range of 10-90% of the full scale load. The sample was held between grips having a front and back face measuring 1 inch (25.4 millimeters)×3 inches (76 millimeters). The grip faces were rubberized, and the longer dimension of the grip was perpendicular to the direction of pull. The grip pressure was pneumatically maintained at a pressure of 60 to 80 pounds per square inch. The tensile test was run at a 20 inches per minute rate with a gauge length of 4 inches and a break sensitivity of 40%. Three samples were tested along the machine-direction (“MD”) and three samples were tested by along the cross direction (“CD”). In addition, the ultimate tensile strength (“peak load”), and peak elongation was also recorded.

Stretch-to-Stop

The testing was done on a Sintech. constant rate of extension tester 2/S with a Renew MTS mongoose box (controller) using TESTWORKS 4.08b software (MTS Corp, of Eden Prairie, Minn.). The percent elongation of the material at a load of 2000 grams-force was determined as described below. Such measurements are determined using the “strip elongation test”, which is substantially in accordance with the specifications of ASTM D5035-95. The test uses two clamps, each having two jaws with each jaw having a facing in contact with the sample. The clamps hold the material in the same plane and move apart at a specified rate of extension. A sample size of 3 inches in the cross-machine direction by 7 inches in the machine direction was selected. The grip size was 3 inches in width, and intermeshing grips were utilized so that material would not slip while tested. The grip separation was 4 inches. The samples were loaded so that the machine direction of the sample was in the vertical direction. A preload of approximately 5 to 10 grams-force was set. The samples were tested at a crosshead speed of 20 in per minute. The sample was displaced until 2000 grams-force of tension was produced, and then the test was stopped. The test reported the % elongation when 2000 grams-force of tension was produced. Results were reported as an average of three specimens and may be performed with the specimen in the cross direction (CD) and/or the machine direction (MD).

Hysteresis

The hysteresis of the elastic material was determined using a Sintech 1/S apparatus equipped with TESTWORKS software to record data. The elastomeric material was cut into strips, each having a width of three inches and a length of six inches. Both ends of the material were clamped into the opposing jaws of the apparatus, so that one inch of the length on each end of the material was maintained within the jaws and four inches of the length was available for stretching. Each material strip was stretched at a rate of 20 inches per minute to the specified elongation value in the data tables and the area under the curve (representing force×displacement) is measured and recorded as the “loading energy.” The material strip is then allowed to recover to a length where the stretching force is zero. During retraction, the area under the curve is again measured and recorded. This is the “unloading energy.” Hysteresis is determined according to the following equation:

${\%\mspace{14mu}{Hysteresis}} = {\left\lbrack \frac{{loading}\mspace{14mu}{energy}\mspace{14mu}{minus}\mspace{14mu}{unloading}\mspace{14mu}{energy}}{{loading}\mspace{14mu}{energy}} \right\rbrack \times 100\%}$

Example 1

The ability to form an elastic composite from first and second nonwoven-film laminates was demonstrated. The first laminate was formed from a film containing 95 wt % of an elastomer composition and 5 wt % of a thermoplastic composition. The elastomer composition contained 96 wt. % KRATON® MD6673 (Kraton Polymers, LLC of Houston Tex.) and 4 wt. % Standridge Color Corporation (“SCC”) 4837. KRATON® MD6673 contains approximately 68 wt. % of a styrene-ethylene-butylene-styrene (“SEBS”) block copolymer, a tackifier, and polyethylene wax, and has a target melt flow rate of 10 g/10 min (200° C., 5 kg). SCC 4837 is a pigment containing titanium dioxide blended with polyethylene. The thermoplastic composition contained 96% Standridge Color Corporation (“SCC”) 25609 and 4 wt. % SCC 4837. SCC 25609 includes approximately 50 wt. % EVA resins (ExxonMobil) and approximately 50 wt. % KS357P polypropylene copolymer (Basell). The facing of the first laminate was a 20 gsm meltblown web containing 60 wt. % DNDA 1082 NT-7 (Dow Chemical) and 40 wt. % VISTAMAXX™ 2330 (ExxonMobil). VISTAMAXX™ 2330 is a polyolefin copolymer/elastomer with a melt flow rate of 285 g/10 min and a density of 0.868 g/cm³. DNDA 1082 NT-7 is a linear low density polyethylene resin with a melt index of 155 g/10 min (190° C., 2.16 kg), a density of 0.933 g/cm³, and a melting point of 257° F. The meltblown web had a peak load in the cross-machine direction of about 113 grams-force per inch.

After compounding, the elastomeric film for the first laminate was formed to a basis weight of 18 gsm using a 20″ wide co-extruding film die. The elastomeric composition of the film was fed to the extruder at a spin pump speed of 5.5 rpm and a hose and die temperature of about 450° F. The thermoplastic component of the film was fed to the extruder at a speed of 4.2 rpm and a hose temperature of about 380° F. The meltblown web was formed to a basis weight of 20 gsm using a 20″ wide meltblown system having 30 capillaries per inch of die width at a spin pump speed of 25.0 rpm, an air temperature of about 650° F., and a die temperature of about 480° F. To form the first laminate, the meltblown web was formed on a forming wire moving at a speed of 65 feet per minute. The film was then extruded onto the meltblown web and was suction forced and nipped onto the film while still molten. Vacuum pressures of 1″ H₂O to 15″ H₂O were used for the suction application.

The second laminate was formed from a film containing 100 wt % of an elastomer composition. The elastomer composition contained 96 wt. % KRATON® MD6673 and 4 wt. % SCC 4837. The facing of the second laminate was a 22 gsm polypropylene thermal bonded carded web made by Kimberly-Clark. The bonded carded web had a peak load in the cross-machine direction of about 195 grams-force per inch. For the second laminate, after compounding, the elastic film was formed to a basis weight of 19 gsm using a 14″ wide co-extruding film die. The film polymer was fed to the extruder at a spin pump speed of 30 rpm and a hose and die temperature of about 450° F. The bonded carded web was supplied by a roll and was unwound into the process at a speed of 65 feet per minute. The film was extruded onto the thermal bonded carded web was then suction forced and nipped onto the film layer while still molten. Vacuum pressures of 1″ H₂O to 15″ H₂O were used for the suction application.

To form the final composite, the first and second laminates were fed into a groove roll system having 5 grooves per inch of width, with the film sides of each incoming composite facing each other, at a speed of about 65 feet per minute. The grooves were engaged to a depth of 0.168 inches of interference. The groove roll system was not heated. The laminates fused together in the groove roll system, forming an multi-layered elastomeric sheet, which was then wound into a roll. The content and material properties achieved for this composite are shown in Tables 1 and 2.

TABLE 1 Content of Laminates Second Second Laminate Laminate Facing First Laminate First Laminate Film Basis Basis Final Composite Groove Roll Total Film Basis Facing Basis Weight Weight Basis Weight Engagement Weight (gsm) Weight (gsm) (gsm) (gsm) (gsm) (inches) 18 20 19 22 79 0.168

TABLE 2 Material Properties CD Composite Composite CD Composite Stretch-to- Hysteresis CD Composite Peak Load Stop (Elongation @ at 100% Peak Load (g_(f) per inch) 2,000 g_(f)) (%) elongation (%) (g_(f) per inch) 1141 333 54 1867

Example 2

A composite was formed as described in Example 1, except that the groove roll interference engagement being 0.224 inches. The resulting material properties are set forth below in Table 3.

TABLE 3 Material Properties CD Composite Composite CD Composite Stretch-to-Stop Hysteresis CD Composite Peak Load (Elongation @ at 100% elongation Peak Load (g_(f) per inch) 2,000 g_(f)) (%) (%) (g_(f) per inch) 926 300 49 1724

Example 3

A composite was formed as described in Example 1, except that the groove roll interference engagement being 0.280 inches. The resulting material properties are set forth below in Table 4.

TABLE 4 Material Properties CD CD Composite Composite Composite Stretch-to-Stop Hysteresis CD Composite Peak Load (Elongation @ 2,000 g_(f)) at 100% Peak Load (g_(f) per inch) (%) elongation (%) (g_(f) per inch) 789 427 42 1744

Example 4

A composite was formed as described in Example 1, except that the groove roll interference engagement being 0.336 inches. The resulting material properties are set forth below in Table 5.

TABLE 5 Material Properties CD CD Composite Composite Composite Stretch-to-Stop Hysteresis CD Composite Peak Load (Elongation @ 2,000 g_(f)) at 100% Peak Load (g_(f) per inch) (%) elongation (%) (g_(f) per inch) 762 445 42 1504

While the invention has been described in detail with respect to the specific embodiments thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing, may readily conceive of alterations to, variations of, and equivalents to these embodiments. Accordingly, the scope of the present invention should be assessed as that of the appended claims and any equivalents thereto. 

What is claimed is:
 1. An elastic composite comprising: a first laminate that contains a first nonwoven facing and an elastic film, wherein the nonwoven facing has a basis weight of about 45 grams per square meter or less and a peak load of about 350 grams-force per inch or less in the cross-machine direction; and a second laminate containing a second nonwoven facing and a thermoplastic film, wherein the first laminate and second laminate are joined together so that the elastic film is bonded and positioned adjacent to the thermoplastic film.
 2. The elastic composite of claim 1, wherein the first nonwoven facing has a basis weight of from about 2 to about 20 grams per square meter.
 3. The elastic composite of claim 1, wherein the first nonwoven facing has a peak load of from about 50 to about 300 grams-force per inch in the cross-machine direction.
 4. The elastic composite of claim 1, wherein the first nonwoven facing has a peak load of from about 3000 grams-force per inch or less in the machine direction.
 5. The elastic composite of claim 1, wherein the composite exhibits a peak elongation of about 75% or more in the machine direction, the cross-machine direction, or both.
 6. The elastic composite of claim 1, wherein the composite exhibits a peak elongation of from about 150% to about 500% in the machine direction, the cross-machine direction, or both.
 7. The elastic composite of claim 1, wherein the first nonwoven facing is formed from a composition that contains a polyolefin.
 8. The elastic composite of claim 1, wherein about 55 wt. % or more of the polymer content of the elastomeric composition is constituted by at least one substantially amorphous elastomer.
 9. The elastic composite of claim 8, wherein the elastomer includes styrene-butadiene, styrene-isoprene, styrene-butadiene-styrene, styrene-isoprene-styrene, styrene-(ethylene-butylene), styrene-(ethylene-propylene), styrene-(ethylene-butylene)-styrene, styrene-(ethylene-propylene)-styrene, styrene-(ethylene-butylene)-styrene-(ethylene-butylene), styrene-(ethylene-propylene)-styrene-(ethylene-propylene), and styrene-ethylene-(ethylene-propylene)-styrene, or a combination thereof.
 10. The elastic composite of claim 1, wherein the first nonwoven facing includes a meltblown web.
 11. The elastic composite of claim 1, wherein the second nonwoven facing has a basis weight of about 45 grams per square meter or less and a peak load of about 350 grams-force per inch in the cross-machine direction or less.
 12. The elastic composite of claim 1, wherein the thermoplastic film is formed from an elastomeric composition.
 13. The elastic composite of claim 1, wherein polyolefins constitute about 55 wt. % or more of the polymer content of the thermoplastic film.
 14. An absorbent article comprising the composite of claim
 1. 15. The absorbent article of claim 14, wherein the article comprises a waist band, leg band, side panel, containment flap, or a combination thereof, one or more of which is formed from the composite. 